I’m now inducted on the HSBNE table saw which means I’m allowed to use it unsupervised. This means I can now cut up sheets as I need them and have progressed further along with enclosing the battery cage. I’ve now enclosed the majority of the battery cage with 1.2mm aluminium sheets.
For the front and bottom of the battery cage, I wanted to use a single piece for strength and to aid with waterproofing. This was because the bottom front of the battery cage is the most likely to see water and debris flicking up from the road. This piece was cut to size then bent to 90 degrees using some clamps and a hammer as HSBNE doesn’t have a pan brake (yet!).
Once the sheet was bent to about a 90 degree angle, it was then clamped into place onto the bike. I drilled holes along the battery cage frame sections so I could pop rivet the sheet onto the frame. Now that most of the sides are in place, I need to tidy up some of the rough edges and seal the inside.
My new head light also arrived and by happenstance it fits! I had to bend the aluminium mounting bracket slightly but otherwise it bolted right in. I need double check, but at first glance I don’t think the integrated indicator lights meet the ADRs. I may need to install some additional front facing indicator lights to meet those requirements. I’m very happy with the look of the headlight though.